Tyler Wisniewski

Mechanical Engineering Student at Cornell University

Design, Analysis, and Manufacturing of Low-Cost Carbon Fiber Surfboard Fins

Executive Summary

This project aimed to democratize high-performance surf equipment by designing and manufacturing carbon fiber fins at a fraction of the market cost. Using Computational Fluid Dynamics (CFD) for aerodynamic optimization and Finite Element Analysis (FEA) for structural validation, I developed a manufacturing process using forged carbon fiber and 3D-printed split molds.

Key Results:

  • Cost Reduction: Produced for $11.16/set (vs. $150+ market rate).
  • Performance: Validated Margin of Safety of 1.73 under hydrodynamic loads.
  • Material Strength: Achieved tensile yield strength of 358 MPa (exceeding industry baseline).

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